CA2967816C - Electrochemical sensor for monitoring under-deposit corrosion - Google Patents
Electrochemical sensor for monitoring under-deposit corrosion Download PDFInfo
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Abstract
An under-deposit corrosion (UDC) sensor includes a probe body with a curved concave probe surface that may have pre-deposited or in-situ formed thereon a material that accelerates the process of under deposit corrosion. The UDC sensor uses electrochemically-based localized monitoring techniques for assessing under-deposit pitting corrosion and the effectiveness of chemical treatment programs that mitigate under-deposit corrosion in well tubing, pipelines, vessels, and/or tanks.
Description
ELECTROCHEMICAL SENSOR FOR
MONITORING UNDER-DEPOSIT CORROSION
TECHNICAL FIELD
[0001] The invention relates to devices and methods for monitoring the corro-sion of metals, and, in one non-limiting aspect, more particularly relates to devices and methods for monitoring the under-deposit corrosion of metals in tubing, pipelines, vessels and/or tanks.
TECHNICAL BACKGROUND
MONITORING UNDER-DEPOSIT CORROSION
TECHNICAL FIELD
[0001] The invention relates to devices and methods for monitoring the corro-sion of metals, and, in one non-limiting aspect, more particularly relates to devices and methods for monitoring the under-deposit corrosion of metals in tubing, pipelines, vessels and/or tanks.
TECHNICAL BACKGROUND
[0002] Under-deposit corrosion (UDC) is a serious problem in oil and gas transmissions lines, tubing, tanks, and separation vessels worldwide that has had a serious impact on pipeline operations and production, and health, safety and environment (HS&E) compliance. Despite the fact that this has been a persistent problem in the industry, there has been little work conducted towards develop-ment of a reliable monitoring method for UDC.
[0003] UDC is sometimes called "cell corrosion", and is typically very aggres-sive and localized, causing deep penetration of the metal surface with lesser general corrosion in the surrounding areas. Due to surface deposits, electrical imbalance or some other initiating mechanism, all corrosion factors attack a select number of individual sites. In some cases, pitting is extended throughout the entire metal surface, giving it an irregular or very rough surface profile. In other instances, pits are concentrated in specific areas, leaving the majority of the metal surface in like-new condition. Galvanized pipe is particularly highly susceptible to UDC.
[0004] It is difficult to build a probe where one can ensure that localized corro-sion occurs. It would be advantageous if a new sensor or probe were discovered that would be an improvement over the presently known probes and methods for monitoring UDC.
5 PCT/US2015/060678 SUMMARY
[0005] There is provided, in one non-limiting embodiment, an under-deposit corrosion (UDC) sensor that includes a probe body; a curved concave probe surface of constant radius comprising at least one reference electrode surface, at least one working electrode surface, and at least one counter electrode surface;
where the respective electrode surfaces are electrically insulated one from each other. The UDC sensor further includes a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter elec-trode surface, which porous, electrically insulating layer conducts ions there-through. There is no porous, electrically insulating layer over the at least one working electrode surface. An electrically conductive lead is electrically attached to each respective electrode surface.
[0005] There is provided, in one non-limiting embodiment, an under-deposit corrosion (UDC) sensor that includes a probe body; a curved concave probe surface of constant radius comprising at least one reference electrode surface, at least one working electrode surface, and at least one counter electrode surface;
where the respective electrode surfaces are electrically insulated one from each other. The UDC sensor further includes a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter elec-trode surface, which porous, electrically insulating layer conducts ions there-through. There is no porous, electrically insulating layer over the at least one working electrode surface. An electrically conductive lead is electrically attached to each respective electrode surface.
[0006] In an alternate non-limiting embodiment there is provided a system for online monitoring under-deposit corrosion in real time which system includes a structure having a concave, curved bottom surface of radius R, where the struc-ture is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a container, and/or a tank. The system further includes a UDC sensor that comprises a probe body; a curved concave probe surface of constant radius R
comprising at least one reference electrode surface, at least one working elec-trode surface, and at least one counter electrode surface; where the respective electrode surfaces are electrically insulated one from each other. The UDC
sensor further includes a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter electrode surface, which porous, electrically insulating layer conducts ions therethrough. There is no porous, electrically insulating layer over the at least one working electrode sur-face. The UDC sensor also comprises an electrically conductive lead electrically attached to each respective electrode surface. The system also includes a machine electrically connected to and configured to receive measurements from the electrically conductive leads, and further configured to measure and/or ana-lyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electri-cal charge, and combinations thereof. The under-deposit corrosion sensor is mounted in the bottom of the structure so that the curved concave probe surface is flush with the concave, curved bottom surface of the structure.
comprising at least one reference electrode surface, at least one working elec-trode surface, and at least one counter electrode surface; where the respective electrode surfaces are electrically insulated one from each other. The UDC
sensor further includes a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter electrode surface, which porous, electrically insulating layer conducts ions therethrough. There is no porous, electrically insulating layer over the at least one working electrode sur-face. The UDC sensor also comprises an electrically conductive lead electrically attached to each respective electrode surface. The system also includes a machine electrically connected to and configured to receive measurements from the electrically conductive leads, and further configured to measure and/or ana-lyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electri-cal charge, and combinations thereof. The under-deposit corrosion sensor is mounted in the bottom of the structure so that the curved concave probe surface is flush with the concave, curved bottom surface of the structure.
[0007] Further in another non-restrictive version, there is provided a method for measuring under-deposit corrosion, where the method includes utilizing a system for monitoring under-deposit corrosion in real time as described in the previous paragraph. The method involves measuring and/or analyzing the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical charge, and combinations thereof.
BRIEF DESCRIPTION OF THE DRAWING
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a cross-sectional perspective view of a short section of pipe having the under-deposit corrosion sensor mounted on the bottom thereof illustrating how the deposit in the pipe is formed in the curved concave probe surface;
[0009] FIG. 2 is a cross-sectional, side profile view of another non-limiting embodiment of the under-deposit corrosion sensor viewed in a direction parallel to a pipe; although a pipe is not shown;
[0010] FIG. 3 is a top plan view of the under-deposit corrosion sensor of FIG. 2 showing a deposit in the curved concave probe surface, where the footprint of the under-deposit corrosion sensor is circular;
[0011] FIG. 4 is a cross-sectional, side profile view of the embodiment of the under-deposit corrosion sensor of FIG. 7 viewed in a direction perpendicular to a pipe; although a pipe is not shown;
[0012] FIG. 5 is a top plan view of the under-deposit corrosion sensor of FIG. 2 that shows no deposit in the curved concave probe surface, where the footprint of the under-deposit corrosion sensor is circular;
[0013] FIG. 6 is a cross-sectional, side profile view of the under-deposit corro-sion sensor of FIG. 1 showing an outline of the inner diameter of a pipe under which the sensor may be monitored, where the radius (R) and diameter (D) of the pipe are schematically illustrated, as well as the arc or angle (A) of the deposit within the cross-section of the pipe and the depth (d) of the deposit; and
[0014] FIG. 7 illustrates top and cross-sectional perspective views of another non-limiting embodiment of the under-deposit corrosion sensor configured to fit into the bottom of a conventional, cylindrical pipe, where the concave probe surface has a roughly rectangular or "dog tag"-like shape, where FIGS. 70 and 7D are cross-sectional perspective views and FIGS. 7A and 7B are top views thereof, respectively, and where FIGS. 7A and 7B do not have a deposit on the working electrode and FIGS. 7B and 7D have a deposit on the working electrode.
[0015] It should be appreciated that the Figures are not necessarily to scale, and that certain features may be exaggerated or may not be in proportion for purposes of illustration, and the invention is not necessarily so limited.
DETAILED DESCRIPTION
DETAILED DESCRIPTION
[0016] A novel under-deposit corrosion (UDC) sensor has been discovered that may use electrochemical monitoring techniques for assessing UDC and the effec-tiveness of chemical treatment programs that prevent, inhibit or mitigate UDC
in common places where it occurs such as metal tubing, pipelines, vessels, tanks and the like. The probe also uses localized monitoring techniques which allow for rapid detection of the pitting corrosion. This UDC probe will help operators meet their goal of reducing the UDC throughout the field and improve operational effi-ciency by providing better monitoring and control of UDC.
in common places where it occurs such as metal tubing, pipelines, vessels, tanks and the like. The probe also uses localized monitoring techniques which allow for rapid detection of the pitting corrosion. This UDC probe will help operators meet their goal of reducing the UDC throughout the field and improve operational effi-ciency by providing better monitoring and control of UDC.
[0017] Operation of the UDC sensor involves the in-situ or pre-deposited layer of a deposit under which corrosion is expected or likely to occur. In one non-limiting embodiment, the size of the probe with the curvature of constant radius (R, see FIG. 6), such as to result in a deposit over a curvature (an angle or arc A
of 1-120 , again see FIG. 6) necessary to obtain a 0.01 mm-1 cm thick deposit, which thickness will vary depending on the size of the UDC probe relative to the actual pipe diameter (D) to be monitored. The deposited material may be from an actual pipe that is pre-deposited or formed in situ on the electrochemical probe where UDC occurs.
of 1-120 , again see FIG. 6) necessary to obtain a 0.01 mm-1 cm thick deposit, which thickness will vary depending on the size of the UDC probe relative to the actual pipe diameter (D) to be monitored. The deposited material may be from an actual pipe that is pre-deposited or formed in situ on the electrochemical probe where UDC occurs.
[0018] The probe described herein will allow for the electrochemical monitoring of localized corrosion and will draw upon previous work on localized corrosion monitoring. Unlike the probe described herein, the probe of U.S. Patent Applica-tion 2008/0134770 does not have the ability for direct under-deposit corrosion measurement; instead, the deposit removal probe of this published patent application monitors the effectiveness of a chemical at removing deposits from the internal surface of a pipeline used to transport fluids, which probe comprises a chamber constructed from mesh having a pore size sufficient to retain a sample of said deposit in said chamber while also allowing the deposit to be removed from the chamber with the action of the chemical and liquid flow through the pipeline and methods of using the probe to determine the effectiveness of a chemical at removing deposits from the internal surface of a pipeline and monitor corrosion rates of surfaces in contact with the deposit and in the bulk fluid.
[0019] The probe described herein provides a method of collecting data and measurement as part of a unique electrochemical method for monitoring UDC by using a special design feature such as pipe curvature to ensure that the UDC
occurs over an extended surface area. Pitting corrosion is measured using an appropriate localized corrosion method that will record localized corrosion events in real time. The device of U.S. Patent Application 2008/0134770 cannot do this.
occurs over an extended surface area. Pitting corrosion is measured using an appropriate localized corrosion method that will record localized corrosion events in real time. The device of U.S. Patent Application 2008/0134770 cannot do this.
[0020] There is no alternative method currently available utilizing a probe for monitoring UDC. Other methods that employ probes for general corrosion (e.g.
linear polarization resistance (LPR), electrical resistance (ER)) include micro-scopic examination of coupon surfaces. Additional ways for monitoring pipeline corrosion include various inspection methods that typically involve techniques such as ultrasound, magnetic flux or eddy current. These methods are difficult to utilize for non-piggable pipelines. A "non-piggable" pipeline is one that cannot be traversed by a "pig", that is a device with blades or brushes inserted into a pipe-line for travelling a length thereof for cleaning purposes, or which may have other equipment or instrumentation to gather data. The method using the UDC probe described herein will allow for quick detection of localized corrosion in situ.
linear polarization resistance (LPR), electrical resistance (ER)) include micro-scopic examination of coupon surfaces. Additional ways for monitoring pipeline corrosion include various inspection methods that typically involve techniques such as ultrasound, magnetic flux or eddy current. These methods are difficult to utilize for non-piggable pipelines. A "non-piggable" pipeline is one that cannot be traversed by a "pig", that is a device with blades or brushes inserted into a pipe-line for travelling a length thereof for cleaning purposes, or which may have other equipment or instrumentation to gather data. The method using the UDC probe described herein will allow for quick detection of localized corrosion in situ.
[0021] One suitable manner of measuring UDC is to utilize the UDC probe described herein in a pipe line application, especially in piggable pipelines.
Various embodiments of the UDC sensor are schematically outlined in FIGS. 1-7 as will be described in more detail below. One feature of the UDC sensor or probe is that it uses electrochemistry to monitor under-deposit corrosion. Another fea-ture of the UDC probe is the presence of a curvature corresponding to pipe diameter in which it is installed so that it may measure UDC below an actual deposit in the pipeline or other structure (e.g. a tubing, a conduit, a pipeline, a vessel, a tank, a container, and other process equipment.
Various embodiments of the UDC sensor are schematically outlined in FIGS. 1-7 as will be described in more detail below. One feature of the UDC sensor or probe is that it uses electrochemistry to monitor under-deposit corrosion. Another fea-ture of the UDC probe is the presence of a curvature corresponding to pipe diameter in which it is installed so that it may measure UDC below an actual deposit in the pipeline or other structure (e.g. a tubing, a conduit, a pipeline, a vessel, a tank, a container, and other process equipment.
[0022] An advantage of the UDC sensor and its method of use is that the deposited material that creates UDC is deposited in-situ on the probe. UDC
deposit materials include, but are not necessarily limited to, ferrous sulfide (iron sulfide or FeS), ferrous oxide (FeO), ferrous carbonate (FeCO3), silicate, and combinations thereof. These deposits may also include, and typically include, organic material which may include, but not necessarily be limited to, asphal-tenes, paraffins, biofilms, and combinations thereof. Of course, water is also typically a component of these deposits.
deposit materials include, but are not necessarily limited to, ferrous sulfide (iron sulfide or FeS), ferrous oxide (FeO), ferrous carbonate (FeCO3), silicate, and combinations thereof. These deposits may also include, and typically include, organic material which may include, but not necessarily be limited to, asphal-tenes, paraffins, biofilms, and combinations thereof. Of course, water is also typically a component of these deposits.
[0023] Using the appropriate pre-deposited material or in situ-formed deposit with the UDC sensor described herein ensures that localized corrosion will occur on the probe. The probe directly measures the under-deposit corrosion and pro-vides a method of assessing the effectiveness of a chemical treatment applied, for instance the continuous, intermittent or regular introduction of a corrosion inhibitor. The UDC sensor is intended for applications in pipelines and process vessels where stagnant flow causes under-deposit corrosion in the oil and gas industry. While the method is particularly suitable for the oil and gas industry, there are a number of other industries such as petroleum refining and petrochemi-cals and water treatment where under-deposit corrosion also occurs and this method and probe can be used for these industries.
[0024] In more detail, FIGS. 2 and 6 illustrate a cross-sectional, side profile view of one non-limiting embodiment of a under-deposit corrosion sensor 10 that has a probe body 12 with a curved concave probe surface 14 on the top thereof (in the orientation of FIG. 1) which has a constant radius R (see FIG. 6) The curved concave probe surface 14 has a reference electrode (RE) surface 16, a working electrode (WE) surface 18 and a counter electrode (CE) surface 20. The respective electrode surfaces are electrically insulated one from each other with any suitable electrically insulating material 22, including, but not necessarily limited to plastic, ionic membranes, glass frits, or other ionically conductive materials or ionically conductive films and combinations thereof. There is an electrically insulating, porous layer 24 over the electrode surfaces 16 and 20, which electrically insulating, porous layer conducts ions therethrough, which may be any suitable film or membrane including, but not necessarily limited to, a glass frit, ionic crystals, solid electrolytes and combinations of these. Note that there is no porous, electrically insulating layer 24 over WE surface 18.
[0025] The WE surface 18 may be relatively large compared to the smaller RE
surface 16, and may be made of carbon steel, including, but not necessarily limited to C1018, X65, 01010 and the like. In one non-limiting embodiment, the material of the WE surface 18 may be similar or identical to the material of the pipe 28 or vessel or other structure in which it is mounted. The pre-formed or pre-deposited deposit or in situ-formed deposit 26 is deposited on the WE surface 18.
The deposited material 26 is of a given thickness and may be generally flush with the pipe surface; see also FIGS. 1, 2 and 6.
surface 16, and may be made of carbon steel, including, but not necessarily limited to C1018, X65, 01010 and the like. In one non-limiting embodiment, the material of the WE surface 18 may be similar or identical to the material of the pipe 28 or vessel or other structure in which it is mounted. The pre-formed or pre-deposited deposit or in situ-formed deposit 26 is deposited on the WE surface 18.
The deposited material 26 is of a given thickness and may be generally flush with the pipe surface; see also FIGS. 1, 2 and 6.
[0026] The WE surface 18 is separated from the counter electrode surface 20, shown as the outer-most electrode, by any suitable insulating material 22, as previously described. The CE surface 20 is exposed to water and is separated from under-deposit material 26 by means of a suitable porous, electrically insulat-ing material, e.g. a glass frit 24. In FIG. 5, which is a top-down or plan view of the UDC sensor 10 of FIGS. 1 and 2, the porous, electrically insulating layer 24 cov-ering the CE electrode 20 is noted as 24/20 and the porous, electrically insulating layer covering the RE electrode 16 is noted as 24/16.
[0027] It will be appreciated that the geometric configuration of the RE
16, WE
18 and CE 20 need not be as shown in FIGS. 5 or 7, but may have different shapes, relative sizes, and relative positions from those shown. It is expected that the UDC sensor 10 will work best when the WE 18 has a relatively larger surface area compared to the RE 16 and the CE 20. It is also expected that the UDC
sensor 10 will work best when RE 16 is positioned within the shape of the WE
18, which in turn is positioned within the shape of CE 20, although other relative positions may be found to work.
16, WE
18 and CE 20 need not be as shown in FIGS. 5 or 7, but may have different shapes, relative sizes, and relative positions from those shown. It is expected that the UDC sensor 10 will work best when the WE 18 has a relatively larger surface area compared to the RE 16 and the CE 20. It is also expected that the UDC
sensor 10 will work best when RE 16 is positioned within the shape of the WE
18, which in turn is positioned within the shape of CE 20, although other relative positions may be found to work.
[0028] The under-deposit corrosion sensor 10 also has electrically conductive leads 36, 38 and 40 electrically attached to each respective electrode surface 16, 18 and 20. These leads 36, 38 and 40 are connected to a machine that is config-ured to receive measurements from the electrically conductive leads, and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resis-tance (LPR), localized corrosion rate, electrical resistance (ER), electrical charge, and combinations thereof. The machine may be any device known in the art to take measurements and provide analysis of corrosion events, such as those described in one or more of the following issued US Patents assigned to Baker Hughes Incorporated:
= U.S. Pat. No. 6,280,603 ¨ Electrochemical Noise Technique for Corrosion, V. Jovancicevic, = U.S. Pat. No. 7,368,050 ¨ Quantitative Transient Analysis of Localized Corrosion, V. Jovancicevic, W. Y. Mok, C. M. Menendez and P. Ham-monds, 2008;
= U.S. Pat. No. 7,622,030 ¨ General and Localized Corrosion Rate Meas-urements, R.P. Gill, V. Jovancicevic, WY. Mok and P. Hammonds, 2009;
= U.S. Pat. No. 7,686,938 ¨ Quantitative, Real Time Measurements of Localized Corrosion Events, R.P. Gill, V. Jovancicevic, W. Y. Mok and P.
Hammonds, 2010;
= U.S. Pat. No. 7, 713,405 ¨ Quantitative Transient Analysis of Localized Corrosion, V. Jovancicevic, C. M. Menendez, P. Hammonds and W Y.
Mok, 2010;
= U.S. Pat. No. 8,133,383¨ Localized Corrosion Monitoring Device for Limited Conductivity Fluids, P. Hammonds and V. Jovancicevic, 2012.
= U.S. Pat. No. 6,280,603 ¨ Electrochemical Noise Technique for Corrosion, V. Jovancicevic, = U.S. Pat. No. 7,368,050 ¨ Quantitative Transient Analysis of Localized Corrosion, V. Jovancicevic, W. Y. Mok, C. M. Menendez and P. Ham-monds, 2008;
= U.S. Pat. No. 7,622,030 ¨ General and Localized Corrosion Rate Meas-urements, R.P. Gill, V. Jovancicevic, WY. Mok and P. Hammonds, 2009;
= U.S. Pat. No. 7,686,938 ¨ Quantitative, Real Time Measurements of Localized Corrosion Events, R.P. Gill, V. Jovancicevic, W. Y. Mok and P.
Hammonds, 2010;
= U.S. Pat. No. 7, 713,405 ¨ Quantitative Transient Analysis of Localized Corrosion, V. Jovancicevic, C. M. Menendez, P. Hammonds and W Y.
Mok, 2010;
= U.S. Pat. No. 8,133,383¨ Localized Corrosion Monitoring Device for Limited Conductivity Fluids, P. Hammonds and V. Jovancicevic, 2012.
[0029] FIG. 1 is a cross-sectional perspective view of a short length of pipe 28 having the under-deposit corrosion sensor 10 mounted on the bottom thereof illustrating how the deposit 26 in the pipe 28 is formed in the curved concave probe surface 14. The radius R of the curved concave probe surface 14 may be the same as the inner radius R or half of the inner diameter 0 of pipe 28, as more clearly shown in FIG. 6. Because these radii are the same and because the UDC
sensor 10 is mounted in the bottom of the structure 28 so that the curved concave probe surface 14 is flush with the concave, curved bottom surface of the structure or pipe 28, the data and measurements collected are much more accurate. It will be appreciated that the size of the UDC sensor 10 shown in FIG. 1 is relatively larger compared to the diameter of the pipe 28 than would likely normally be the case for a commercial embodiment of a UDC sensor, but the relative size is exaggerated for clarity.
sensor 10 is mounted in the bottom of the structure 28 so that the curved concave probe surface 14 is flush with the concave, curved bottom surface of the structure or pipe 28, the data and measurements collected are much more accurate. It will be appreciated that the size of the UDC sensor 10 shown in FIG. 1 is relatively larger compared to the diameter of the pipe 28 than would likely normally be the case for a commercial embodiment of a UDC sensor, but the relative size is exaggerated for clarity.
[0030] In the non-limiting embodiment shown in FIGS. 1 and 6, the curved concave probe surface 14 has a shape that is a partial cylinder, that is, if a cylin-der is imagined lying on its curved side on a horizontal surface, and a horizontal slice is taken from the lower-most portion of the cylinder. This would be the shape of the deposit 26 if it were removed from FIGS. 1 and 6. This shape may also be seen with respect to the non-limiting embodiment shown in FIG. 7, where curved concave probe surface 30 has a "dog tag" like shape or roughly rectangular shape with curved ends. The same reference numerals are used for other parts of the probe 10, although they may have different shapes from other embodiments described and shown herein. FIGS. 70 and 7D are cross-sectional perspective views that illustrate how probe surface 30 that is curved in the pipeline circumfer-ence direction but straight along the axis of the pipeline would appear. FIGS.
and 7B are top views thereof, respectively. FIGS. 7A and 7B do not have a deposit on the WE 18, whereas FIGS. 7B and 7D illustrate a deposit 26 on the WE 18 in each Figure. FIG. 4 is a cross-sectional, side profile view of the embodi-ment of the under-deposit corrosion sensor of FIG. 7 viewed in a direction per-pendicular to a pipe; although a pipe is not shown. The bottom of curved concave probe surface 30 would appear as a straight horizontal line, as shown.
and 7B are top views thereof, respectively. FIGS. 7A and 7B do not have a deposit on the WE 18, whereas FIGS. 7B and 7D illustrate a deposit 26 on the WE 18 in each Figure. FIG. 4 is a cross-sectional, side profile view of the embodi-ment of the under-deposit corrosion sensor of FIG. 7 viewed in a direction per-pendicular to a pipe; although a pipe is not shown. The bottom of curved concave probe surface 30 would appear as a straight horizontal line, as shown.
[0031] Shown in FIGS. 2, 3 and 5 is a different non-limiting embodiment of the UDC sensor 10. FIG. 2 is a cross-sectional, side profile view of another non-limiting embodiment of the under-deposit corrosion sensor 10 viewed in a direc-tion parallel to a pipe, although a pipe is not shown; whereas FIG. 3 is a top plan view of the under-deposit corrosion sensor 10 of FIG. 2 showing a deposit 26 in the curved concave probe surface 14, where the footprint of the under-deposit corrosion sensor is 10 circular. Unlike the embodiment of UDC sensor 10 in FIGS.
4 and 7, in this embodiment the curved concave probe surface 14 is circular and has a shape that is a partial sphere. For instance, if a sphere rested on a horizon-tal surface had the horizontal slice taken from the bottom thereof the resulting shape would be that of deposit 16 in FIGS. 2 and 3. In other words, if deposit was removed from FIGS. 2 and 3, it would have an "inverted dome"-shape.
4 and 7, in this embodiment the curved concave probe surface 14 is circular and has a shape that is a partial sphere. For instance, if a sphere rested on a horizon-tal surface had the horizontal slice taken from the bottom thereof the resulting shape would be that of deposit 16 in FIGS. 2 and 3. In other words, if deposit was removed from FIGS. 2 and 3, it would have an "inverted dome"-shape.
[0032] The embodiments of the UDC sensor 10 shown in all of the Figures would be suitable for use in a flat-bottomed tank or vessel or other structure where there is likely to be stagnant flow of the fluid in the structure.
[0033] The pre-formed deposit or in situ-formed deposit 26 may have a thick-ness ranging from about 0.01 mm independently to about 1 cm; alternatively ranging from about 0.05 mm independently to about 1 mm. Where the term "inde-pendently" is used with respect to a range, it means that any lower threshold may be used together with any upper threshold to form a suitable alternative range. It will be further appreciated that the deposit thickness is independent of the curva-ture, that is the radius R or diameter D.
[0034] Many modifications may be made in the present invention without departing from the scope thereof that are defined only by the appended claims.
For example, certain elements or features per se, or combinations of elements or features thereof other than those specifically set out herein may be found by one of routine skill in the art to be particularly advantageous, in non-limiting instances, different dimensions, positions, relative sizes, metal compositions, deposit com-ponents and compositions, electrodes, porous layers, curved concave probe surface shapes and volumes, etc. other than those mentioned or exemplified are expected to be useful.
For example, certain elements or features per se, or combinations of elements or features thereof other than those specifically set out herein may be found by one of routine skill in the art to be particularly advantageous, in non-limiting instances, different dimensions, positions, relative sizes, metal compositions, deposit com-ponents and compositions, electrodes, porous layers, curved concave probe surface shapes and volumes, etc. other than those mentioned or exemplified are expected to be useful.
[0035] The words "comprising" and "comprises" as used throughout the claims is interpreted "including but not limited to".
[0036] The present invention may suitably comprise, consist or consist essen-tially of the elements disclosed and may be practiced in the absence of an ele-ment not disclosed. For instance, in one non-limiting embodiment, there is pro-vided an under-deposit corrosion sensor consisting essentially of or consisting of a probe body; a curved concave probe surface of constant radius consisting essentially of or consisting of at least one reference electrode surface, at least one working electrode surface, and at least one counter electrode surface, where the respective electrode surfaces are electrically insulated one from each other, and where the under-deposit corrosion sensor further consists essentially of or consists of a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter electrode surface, which porous, electrically insulating layer conducts ions therethrough, where there is no porous, electrically insulating layer over the at least one working electrode surface;
and an electrically conductive lead electrically attached to each respective electrode surface.
and an electrically conductive lead electrically attached to each respective electrode surface.
[0037] In a different non-restrictive version, there may be provided a system for monitoring under-deposit corrosion in real time consisting essentially of or consist-ing of a structure having a concave, curved bottom surface of radius R, where the structure is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a tank, a container and other process equipment and an under-deposit corrosion (UDC) sensor, where the under-deposit corrosion sensor is mounted in the bottom of the structure so that the curved concave probe surface is flush with the concave, curved bottom surface of the structure. The UDC sensor consists essentially of or consists of a probe body; a curved concave probe surface of constant radius R consisting essentially of or consisting of at least one reference electrode surface, at least one working electrode surface, and at least one coun-ter electrode surface, where the respective electrode surfaces are electrically insulated one from each other, and the UDC sensor further consists essentially of or consists of a porous, electrically insulating layer over the at least one reference electrode surface and the at least one counter electrode surface, which porous, electrically insulating layer conducts ions therethrough, where there is no porous, electrically insulating layer over the at least one working electrode surface an electrically conductive lead electrically attached to each respective electrode sur-face. The system additionally consists essentially of or consists of a machine electrically connected to and configured to receive measurements from the elec-trically conductive leads, and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resis-tance, electrical charge and combinations thereof.
[0038] Alternatively an electrically conductive lead electrically attached to each respective electrode surface, there may be provided a method of measuring under-deposit corrosion, the method consisting essentially of or consisting of utilizing the system for monitoring under-deposit corrosion in real time that is described in the previous paragraph, where the method further consists essen-tially of or consists of measuring and/or analyzing the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resistance, electrical charge and combinations thereof.
Claims (19)
1. An under-deposit corrosion sensor (10) comprising:
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer (24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer (24) conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20).
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer (24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer (24) conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20).
2. The under-deposit corrosion sensor (10) of claim 1 where the at least one working electrode surface (18) has a deposit (26) thereon, where the deposit (26) is selected from the group consisting of ferrous sulfide, ferrous oxide, ferrous carbonate, silicate, and combinations thereof.
3. The under-deposit corrosion sensor of (10) claim 2 where the deposit (26) additionally comprises an organic material selected from the group consisting of asphaltenes, paraffins, biofilms, and combinations thereof.
4. The under-deposit corrosion sensor (10) of claim 2 where the deposit (26) has a thickness ranging from 0.01 mm to 1 cm.
5. The under-deposit corrosion sensor (20) of any one of claims 1, 2, 3 or where the curved concave probe surface (14) has a shape selected from the group consisting of a partial cylinder and a partial sphere.
6. The under-deposit corrosion sensor (10) of any one of claims 1, 2, 3 or where the porous, electrically insulating layer (24) is selected from the group consisting of a glass frit, an ionically conductive polymer, ionic crystals, solid electrolytes, and combinations thereof.
7. The under-deposit corrosion sensor (10) of any one of claims 1, 2, 3 or where the working electrode surface (18) and the counter electrode surface (20) each have greater area than the reference electrode surface (16).
8. A system for monitoring under-deposit corrosion in real time comprising:
a structure (28) having a bottom with a shape selected from the group consisting of a flat surface, a concave, curved bottom surface of radius R, and combinations thereof, where the structure (28) is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a tank, a container, and combinations thereof;
an under-deposit corrosion sensor (10) mounted in the bottom of the structure (28) so that the curved concave probe surface (14) is flush with the concave, curved bottom surface of the structure (28), where the under-deposit corrosion sensor (10) comprises:
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius R
comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer (24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer (24) conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20), and a machine electrically connected to and configured to receive measurements from the electrically conductive leads (36, 38, 40), and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resistance, electrical charge and combinations thereof.
a structure (28) having a bottom with a shape selected from the group consisting of a flat surface, a concave, curved bottom surface of radius R, and combinations thereof, where the structure (28) is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a tank, a container, and combinations thereof;
an under-deposit corrosion sensor (10) mounted in the bottom of the structure (28) so that the curved concave probe surface (14) is flush with the concave, curved bottom surface of the structure (28), where the under-deposit corrosion sensor (10) comprises:
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius R
comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer (24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer (24) conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20), and a machine electrically connected to and configured to receive measurements from the electrically conductive leads (36, 38, 40), and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resistance, electrical charge and combinations thereof.
9. The system of claim 8 where at least the at least one working electrode surface (18) of the under-deposit corrosion sensor (10) has a deposit (26) thereon, where the deposit is selected from the group consisting of ferrous sulfide, ferrous oxide, ferrous carbonate, silicate, and combinations thereof.
10. The system of claim 9 where the deposit (26) on the under-deposit corrosion sensor (10) additionally comprises an organic material selected from the group consisting of asphaltenes, paraffins, biofilms, and combinations thereof.
11. The system of claim 9 where the deposit (26) has a thickness ranging from 0.01 mm to 1 cm.
12. The system of any one of claims 8, 9, 10, or 11 where the curved concave probe surface (14) of the under-deposit corrosion sensor (10) has a shape selected from the group consisting of a partial cylinder and a partial sphere.
13. The system of any one of claims 8, 9, 10, or 11 where in the under-deposit corrosion sensor (10) the porous, electrically insulating layer (24) is selected from the group consisting of a glass frit, an ionically conductive polymer, ionic crystals, solid electrolytes, and combinations thereof.
14. The system of any one of claims 8, 9, 10, or 11 where in the under-deposit corrosion sensor (10) the working electrode surface (18) and the counter electrode surface (20) each have greater area than the reference electrode surface (16).
15. A method of measuring under-deposit corrosion, the method comprising utilizing a system for monitoring under-deposit corrosion in real time comprising:
a structure (28) having a bottom with a shape selected from the group consisting of a flat surface, a concave, curved bottom surface of radius R, and combinations thereof, where the structure (28) is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a tank, a container, and combinations thereof;
an under-deposit corrosion sensor (10) mounted in the bottom of the structure (28) so that the curved concave probe surface (14) is flush with the concave, curved bottom surface of the structure (28), where the under-deposit corrosion sensor (10) comprises:
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius R
comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer(24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20), and a machine electrically connected to and configured to receive measurements from the electrically conductive leads (36, 38, 40), and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resistance, electrical charge and combinations thereof;
where the method further comprises measuring and/or analyzing the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical charge and combinations thereof.
a structure (28) having a bottom with a shape selected from the group consisting of a flat surface, a concave, curved bottom surface of radius R, and combinations thereof, where the structure (28) is selected from the group consisting of a pipeline, a tubing, a conduit, a vessel, a tank, a container, and combinations thereof;
an under-deposit corrosion sensor (10) mounted in the bottom of the structure (28) so that the curved concave probe surface (14) is flush with the concave, curved bottom surface of the structure (28), where the under-deposit corrosion sensor (10) comprises:
a probe body (12);
characterized by:
a curved concave probe surface (14) of constant radius R
comprising:
at least one reference electrode surface (16);
at least one working electrode surface (18); and at least one counter electrode surface (20), where the respective electrode surfaces (16, 18, 20) are electrically insulated one from each other;
a porous, electrically insulating layer(24) over the at least one reference electrode surface (16) and the at least one counter electrode surface (20), which porous, electrically insulating layer conducts ions therethrough, where there is no porous, electrically insulating layer (24) over the at least one working electrode surface (18); and an electrically conductive lead (36, 38, 40) electrically attached to each respective electrode surface (16, 18, 20), and a machine electrically connected to and configured to receive measurements from the electrically conductive leads (36, 38, 40), and further configured to measure and/or analyze the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical resistance, electrical charge and combinations thereof;
where the method further comprises measuring and/or analyzing the measurements for data selected from the group consisting of changes in electrical potential, linear polarization resistance, localized corrosion rate, electrical charge and combinations thereof.
16. The method of claim 15 where method additionally comprises forming on the curved concave probe surface (14) of the under-deposit corrosion sensor (10) a deposit (26) selected from the group consisting of ferrous sulfide, ferrous oxide, ferrous carbonate, silicate, and combinations thereof.
17. The method of claim 16 where the deposit (26) on the under-deposit corrosion sensor (10) additionally comprises an organic material selected from the group consisting of asphaltenes, paraffins, biofilms, and combinations thereof.
18. The method of claim 16 where the deposit (26) has a thickness ranging from 0.01 mm to 1 cm.
19. The method of any one of claims 15, 16, 17, or 18 further comprising:
introducing a chemical into the structure; and measuring whether under-deposit corrosion changes after introducing the chemical.
introducing a chemical into the structure; and measuring whether under-deposit corrosion changes after introducing the chemical.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
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| US14/546,442 | 2014-11-18 | ||
| US14/546,442 US9726594B2 (en) | 2014-11-18 | 2014-11-18 | Electrochemical sensor for monitoring under-deposit corrosion |
| PCT/US2015/060678 WO2016081315A1 (en) | 2014-11-18 | 2015-11-13 | Electrochemical sensor for monitoring under-deposit corrosion |
Publications (2)
| Publication Number | Publication Date |
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| CA2967816A1 CA2967816A1 (en) | 2016-05-26 |
| CA2967816C true CA2967816C (en) | 2018-09-25 |
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| CA (1) | CA2967816C (en) |
| SA (1) | SA517381494B1 (en) |
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| US10295508B2 (en) * | 2016-01-06 | 2019-05-21 | Saudi Arabian Oil Company | Integrated system for quantitative real-time monitoring of hydrogen-induced cracking in simulated sour environment |
| US10852225B2 (en) * | 2017-09-01 | 2020-12-01 | Crane Resistoflex | Corrosion indicator for use with a piping system, and a piping system using the corrosion indicator |
| RU2692118C2 (en) * | 2017-09-11 | 2019-06-21 | Общество с ограниченной ответственностью "Баромембранная технология" | Method and device for continuous control of pitting corrosion of metal structures inner walls |
| US11699505B2 (en) | 2018-11-29 | 2023-07-11 | Tata Consultancy Services Limited | Method and system for estimating corrosion inhibitor concentration using a multi-electrode array sensor |
| US11555777B2 (en) | 2019-07-15 | 2023-01-17 | Saudi Arabian Oil Company | Method and system for corrosion simulation and assessment |
| US11085908B1 (en) * | 2019-08-23 | 2021-08-10 | Matergenics, Inc. | Non-destructive testing system for detecting graphitization of iron |
| US11680757B2 (en) * | 2020-07-09 | 2023-06-20 | General Electric Technology Gmbh | System and method for heat exchanger control based on real-time corrosion monitoring |
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| GB9901572D0 (en) * | 1999-01-26 | 1999-03-17 | Integriti Investments Limited | Corrosion detection under lagging |
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| WO2016081315A1 (en) | 2016-05-26 |
| US20160139030A1 (en) | 2016-05-19 |
| US9726594B2 (en) | 2017-08-08 |
| CA2967816A1 (en) | 2016-05-26 |
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